Industrial Carbonization Systems for Biochar or bio-carbon & Thermal Processing

• Logging and woodworking enterprises (with their own feedstock or waste products).
• Producers of fuel wood and energy crops (eucalyptus, bamboo, energy willow, etc.).
• Agricultural enterprises, orchards, and agro-biomass processors (subject to feedstock preparation and applicability for chamber carbonization).
• Companies generating plant-based biomass/carbon-containing feedstock (including some lump waste).
• Investors/operators of BIOCHAR projects (carbon removal projects, soil improvement, ESG) requiring stable quality and process parameter traceability.

• BBQ/HoReCa and retail market.
• Metallurgy.
• Silicon production.
• Activated carbon production.
• BIOCHAR as a soil conditioner/eco-friendly fertilizer (depending on application standards).
• Other industries requiring carbon materials (sorbents, filtration, etc. — based on the customer’s technical specifications).

EKKO-2 is a semi-continuous chamber carbonization (slow pyrolysis) unit equipped with two technological chambers. The process is based on controlled heat supply and the complete neutralization of pyrolysis gases. The thermal energy generated during the neutralization of pyrolysis gases is used for drying the feedstock and maintaining the pyrolysis process, which reduces the need for additional fuel once a stable operating mode is reached.

The main purpose of the EKKO-2 fixed-bed pyrolysis unit is the production of lump charcoal with a minimal content of fine fractions.

A. Processes outside the pyrolysis Unit: 

1. Feedstock size reduction: cutting and splitting, and in some cases crushing and chopping, i.e. reducing the material to an acceptable fraction, which facilitates thermal processes and loading of feedstock into the trolleys;
2. Loading feedstock into the trolleys;
3. Pre-drying of feedstock: forced drying using excess heat from the EKKO-2 process;
4. Charging the trolley into the chamber and removing the trolley with hot charcoal from the chamber;
5. Cooling the charcoal in the trolleys without oxygen access;
6. Discharging charcoal from the trolley, and if required, charcoal stabilization and packaging.

B. Processes inside the pyrolysis Unit: 

• Final drying and initial stage of pyrolysis (100–250°C): removal of moisture and primary pyrolysis products;
• Carbonization (250–450°C);
• Calcination (approximately 450–550°C): applied when higher fixed carbon content is required (Cfix > 83%).

*Transitions between modes occur according to the ACS algorithms and/or by the operator’s decision;

Pre-drying mode: control of the maximum allowable drying temperature of the feedstock, preventing the onset of pyrolysis reactions in the material;

Typical pyrolysis chamber modes: “DRYING”, “PYROLYSIS START”, “PYROLYSIS END”, “CHARCOAL READY”, “RELOADING”.

BIO-CARBON is a vertical moving-bed unit for continuous dry carbonization of biomass. Based on patented technology and full automation, the unit is an industrial asset that produces:

• High-quality charcoal with fixed carbon content (Cfix) from 82% to 95%
• Biochar for agricultural applications
• Industrial charcoal for metallurgy, activated carbon production, semiconductors, and silicon production
• High-potential thermal energy as a by-product

The unit operates 24/7 without technological shutdowns and ensures environmentally friendly production through full neutralization of pyrolysis syngas. 

 The main advantages of BIO-CARBON include: 

• Environmental friendliness: Emissions to the atmosphere consist only of water vapor and CO₂. Pyrolysis gases are fully neutralized at temperatures above 1300°C, eliminating harmful emissions. Compared to traditional methods, which produce up to 4 tons of harmful emissions per 1 ton of charcoal.
• 100% automation: Minimal personnel involvement (1 operator + 1 assistant per shift). Automatic control of all parameters via the 2026 control system.
• Continuous operation: 365 days a year, 24 hours a day, 7 days a week without technological shutdowns.
• Stable product quality: The automated control system ensures consistent characteristics of the produced charcoal.
• Energy efficiency: The unit operates on its own pyrolysis gas; additional fuel is only required during startup (25–50 liters of propane-butane gas). Generates excess heat of 300–1000 kW.
• Low power consumption: BC-2: 8 kW; BC-3: 13.6 kW.
• Compactness: Small footprint with high productivity.
• High reliability: 100% refractory materials, service life of 5–10 years.

There are two main unit models, differing in capacity and dimensions: 

*Note: productivity is specified for a fixed carbon content (Cfix) 82-95%

GreenPower unit is officially operated in more than 39 countries worldwide, including countries in Europe, Asia, Africa, South America, and North America. The unit has obtained environmental operating permits in all of these regions.

The productivity of BIO-CARBON depends on the following key factors: 

1. unit model: BIO-CARBON-2: 60–100 t/month; BIO-CARBON-3: 80–140 t/month
2. Fixed carbon content (Cfix) in the final product: The lower the required Cfix, the higher the productivity. For example, for the BIO-CARBON model:

• At Cfix 80–85%: up to 120–140 t/month
• At Cfix 90–95%: up to 80 t/month

3. Bulk density of the feedstock: Depends on the material density and its particle size. As bulk density increases, the unit productivity increases.
4. Feedstock moisture content: Should be below 15% (maximum 20%). Lower moisture increases productivity, while higher moisture decreases it. Optimal moisture: 10–12%.